Hi, Chipp.
Just curious - did you encounter any difficulties? Did you have to scale up or down to make things work?
I often do similar things for vacuum forming parts or tools; and almost always have some small areas of fileting get hung up.
Great job!
Ron

Yes, there were a few problems. Once I had to scale to 1/10, separate, then join after a fillet had left the object as a Joined srf instead of Solid.

Another time I was trying to create a fillet which effectively blended to 0. I couldn't get the Fillet Set feature to work so I created a 'stop' element which allowed the fillet to be created BEFORE ending in 0. This was not optimum, but based on the overall complexity of the model, wasn't so bad.

FWIW, the whole model was a solid at the end. Impressive how MoI could keep up with so many boolean, fillet and chamfer applications.

Hi Chipp,
Nice stuff. A quick question. When you modeled and setup these types of component cuts, etc, did you just do a straight cut and fillet the edges to give the "separation" effect? Or did you model some type of tolerance gap there, into the cuts also?

I drew a single polyline, radiused it, then offset it the gapwidth with cap ends turned on. Then I just boolean diff'd it. If I wanted to create a 'trench' gap, I would've boolean merged it, then scaled it down on the z direction (height) then boolean unioned.